My Build

[Neverdone]

Been working on building my first bar stool racer. I think it is comming along fairly well. I am using a 125cc 2 stroke motor manual clutch and five speed gear box to power it along. I started using a set of plans for the classic cruiser and modified it from there. I extended my frame and foot plates a little bit, chopped the stool about 3 inches and designed my own motor mount and center section to the frame. I need to fab up an exhaust, finish the brakes, fab the wheely bar and mount a gas tank. I am starting to near the end of the project just need to find a few more parts.
http://i248.photobucket.com/albums/gg164/RumbleWagon/untitled.jpg
Does anyone know where I can get a custom length cable made?

[buggyboy]

I went to my local bike (bicyle) shop and they made me a custom length throttle cable.

[Neverdone]

Thanks for the Tip I am going to check a few places about that tomorrow. Spent a little time tonight to work on fitting the exhaust up. I have the biggest part done I am going to adjust the back a little bit. Gonna run it down closer to the frame and attach to silencer on it it. Fits pretty good I think especially since it is the stock pipe from the dirtbike. Then I need to put on a gas tank and it will be getting closer to done.
http://i248.photobucket.com/albums/gg164/RumbleWagon/stoolpipe.jpg

[Neverdone]

Still haven't had any luck finding a cable for the brakes but I think I have a good idea one how to run a solid rod to run the brakes. Finished the exhaust today other than grinding it down. Don't think that the flow is going to be right though with running those two steep bends. I also need to come up with a new air filter. Dont think that will be too hard thoughhttp://i248.photobucket.com/albums/gg164/RumbleWagon/morestool2.jpghttp://i248.photobucket.com/albums/gg164/RumbleWagon/morestool.jpghttp://i248.photobucket.com/albums/gg164/RumbleWagon/morestool3.jpg

[Terry Skinner]

To fabricate a brake cable: first obtain a stainless steel cable from the local marine supply. then go to the hardware store and get a length of plastic tube such as used to supply water to the ice maker. cut to proper length and take to your favorite bicycle shop. They will silver solder the appropriate ends on. Or go to the local lawnmower shop and see what they have to offer. HTH......Terry

[buggyboy]

Been working on building my first bar stool racer. I think it is comming along fairly well. I am using a 125cc 2 stroke motor manual clutch and five speed gear box to power it along. I started using a set of plans for the classic cruiser and modified it from there. I extended my frame and foot plates a little bit, chopped the stool about 3 inches and designed my own motor mount and center section to the frame. I need to fab up an exhaust, finish the brakes, fab the wheely bar and mount a gas tank. I am starting to near the end of the project just need to find a few more parts.
http://i248.photobucket.com/albums/gg164/RumbleWagon/untitled.jpg
Does anyone know where I can get a custom length cable made?

How much is your custom length?

[Neverdone]

I need a cable 17 inches long

[DGE Motorsports]

Looks good Neverdone but your going to kill yourself on that thing. I hope you like doing donuts!! :laughing:

[Neverdone]

That's the general idea. I think it will be rather interesting when it is done. I have pretty well got my hole street interested in it now.

[DGE Motorsports]

Get some video and post when you finish. Good luck and wear your safety gear.

[DGE Motorsports]

Post some video when you finish. Good luck and wear your safety gear.

[DGE Motorsports]

I look forward to seeing some video when you get it finished. Good luck and wear some good safety gear.

[Neverdone]

I plan on posting up some video when I get it done. I just ordered a dye so that I can cut my axle down and re-thread it. I still need to get the motor running and get some brakes done. Other than that it is pretty well done, just some odds and ends to wrap up. Seems like it is taking forever for me to get it done. It is definitly becoming very popular around my street.

[shoyass]

125 two stroke Nice. Super dangerous.

[Neverdone]

That is the plan....... Strap on the beer bong helmet and go to town

[Neverdone]

So I ran into a serious issue with my progress. I decided it was time to put a chain on the beast and start on that portion, building a tensioner and what not. All along I thought that I had a #41 sprocket on the motor. Well its not. Now I either have a useless back sprocket or front depending on how you look at it. From what I have read it is probably a 428. Where can I find a shop that will make me one of those but small, and can fit on the hub that I have? I sent an email to Mike Bean to see where he had his made from but that was two weeks ago and I still havent heard a reply. Until then the project is basically at a stand still. I have my tank on, need to mount my cup holder, do some grinding, finish my brakes (found a place that sells a do it yourself any length cable kit), basically just tie up loose ends then I am done!!!! Of course paint it too.............. Here is what I got so far. http://i248.photobucket.com/albums/gg164/RumbleWagon/paintedpipe.jpg

[pertj]

So I ran into a serious issue with my progress. I decided it was time to put a chain on the beast and start on that portion, building a tensioner and what not. All along I thought that I had a #41 sprocket on the motor. Well its not. Now I either have a useless back sprocket or front depending on how you look at it. From what I have read it is probably a 428.

Is this what you have: # 41 rear sprocket and # 428 engine sprocket ?

Wou don't know who made the engine, so that you could check for an alternative engine sprocket ? Sprockets are made in many different versions, and if you knew the engine, you could be lucky and cross-reference it to another enigine with the correct sprocket ?

What you perhaps (?) also could do, is to turn down the thickness of the 428 engine sprocket, it uses a 5/16" wide roller vs. the # 41 which is 1/4".
You could then try to use a # 41 chain, they have the same pitch, 1/2" but be aware that the diameter of the #41 rollers are slightly smaller than the # 428, 0.305" vs. 0.335".
This would mean that the # 41 rollers will not be in contact the way they should on the # 428 engine sprocket, which could mean that the chain and sprockets would wearout faster than normal, or that the chain could disengage from the sprocket. Perhaps a little dangerous ?

I would have first tried to cross-ref the engine sprocket.

[Randy on a Stool]

428 is a common chain on a motorcycle. The 35 and the 40/41 is a common industrial size. The two don't mix. Finding a sprocket w/ different pitch on the motrocycle engine would be tough. I would just find the right tooth size sprocket for the rear of a motorcycle, and adapt that to your hub on rear axle. Most of those are a six bolt setup, and once you've adapted to that, you could swap out to different tooth sizes and change gear ratio as needed. Turn your hub on a lathe and you're good to go

[DGE Motorsports]

They do make #428 sprockets for shifter carts but unfortunately they are only made for 40mm and 50mm axles from what I can tell which would require you to change a whole bunch of parts or you could have a reducer sleeve made that would fit your axle which would probably be a whole bunch cheaper. The sprockets can be found here. (http://host179.ebm.bestsoftwarehost.com/IW_Products.m4p.pvx?;MULTI_ITEM_SUBMIT)

I have attached a rendering of what the reducer might look like.

[pertj]

428 is a common chain on a motorcycle. The 35 and the 40/41 is a common industrial size. The two don't mix. Finding a sprocket w/ different pitch on the motrocycle engine would be tough. I would just find the right tooth size sprocket for the rear of a motorcycle, and adapt that to your hub on rear axle. Most of those are a six bolt setup, and once you've adapted to that, you could swap out to different tooth sizes and change gear ratio as needed. Turn your hub on a lathe and you're good to go

Well, the pitch is the same, but the tooth size isn't.

I know that many older mopeds and small motorcycles used 40/41 size chains, but if the engine sprockets has the same spline count etc. as the yz engine - who knows ? It would perhaps take some (a lot ?) of research to find out...

Adapting a motorcycle sprocket to the hub is exactly the thing i did on my stool:
http://lh6.ggpht.com/_u7hHZZ7N7jU/SgxuIdbYWpI/AAAAAAAAADI/KfkMvRiy7us/IMG_6283_mod_small.jpg

I had a hard time finding a sprocket with around 40 teeths, most motorcycle sprockets where in the 50-60 or so. I think this sprocket actually is an ATV type of sprocket. Anyway, the sprocket had 6 "lugs" or "arms", so i mounted the sprocket in my lathe, just barely touching the sprocket with the turning iron at the correct bolting diameter on the arms, carefully drilled one hole, bolted up the hub, aligned the sprocket and hub, drilled out the hole on the other side, directly across, bolted in another bolt, and finally drilled out the remaining 4 holes. You can barely see the 4 original holes in the sprocket.

I basically did the same thing to the brake disk, but here i had to turn down / out the center of the disk. So i measured the distance between the mounting "points" on the arms of the brake hub, turned out the center of the disk at the exact same diameter, drilled the mounting holes and bolted the disk to the hub with some counter-sunk screws.

[Neverdone]

They do make #428 sprockets for shifter carts but unfortunately they are only made for 40mm and 50mm axles from what I can tell which would require you to change a whole bunch of parts or you could have a reducer sleeve made that would fit your axle which would probably be a whole bunch cheaper. The sprockets can be found here. (http://host179.ebm.bestsoftwarehost.com/IW_Products.m4p.pvx?;MULTI_ITEM_SUBMIT)

I have attached a rendering of what the reducer might look like.

I could make a reducer, that would not be an issue. You said that sprockets are available here........ Where is here? I looked briefly at your website and did not see them unless I was on the wrong site. All I saw there was rollcages. I am getting a lot closer installed wheely bars last night. Still need to get a brake cable but a shop down the road said that they could get one made for me but it is a couple week turn around. So I am still looking at other options. Thanks everyone for all the help. I did remeasure the sprocket on the motor and I am pretty damn sure that it is a 428

[Neverdone]

Well, the pitch is the same, but the tooth size isn't.

I know that many older mopeds and small motorcycles used 40/41 size chains, but if the engine sprockets has the same spline count etc. as the yz engine - who knows ? It would perhaps take some (a lot ?) of research to find out...

Adapting a motorcycle sprocket to the hub is exactly the thing i did on my stool:
http://lh6.ggpht.com/_u7hHZZ7N7jU/SgxuIdbYWpI/AAAAAAAAADI/KfkMvRiy7us/IMG_6283_mod_small.jpg

I had a hard time finding a sprocket with around 40 teeths, most motorcycle sprockets where in the 50-60 or so. I think this sprocket actually is an ATV type of sprocket. Anyway, the sprocket had 6 "lugs" or "arms", so i mounted the sprocket in my lathe, just barely touching the sprocket with the turning iron at the correct bolting diameter on the arms, carefully drilled one hole, bolted up the hub, aligned the sprocket and hub, drilled out the hole on the other side, directly across, bolted in another bolt, and finally drilled out the remaining 4 holes. You can barely see the 4 original holes in the sprocket.

I basically did the same thing to the brake disk, but here i had to turn down / out the center of the disk. So i measured the distance between the mounting "points" on the arms of the brake hub, turned out the center of the disk at the exact same diameter, drilled the mounting holes and bolted the disk to the hub with some counter-sunk screws.

Can't see your picture but where did you find your sprocket? I can't find one that is even small enough to fit inside my tire diameter. I am willing to use something different on the axle but would rather not if I can get away with it.

[DGE Motorsports]

Here is the link to the sprockets http://www.cometkartsales.com/store/chassis/crg/crgshifter.htm

[Neverdone]

http://i248.photobucket.com/albums/gg164/RumbleWagon/wheelyhieght.jpgupdated picshttp://i248.photobucket.com/albums/gg164/RumbleWagon/wheelybar.jpg

[pertj]

Can't see your picture but where did you find your sprocket? I can't find one that is even small enough to fit inside my tire diameter. I am willing to use something different on the axle but would rather not if I can get away with it.

Hmm, I am using Picasa, I don't know why the picture doesn't show - some settings perhaps ?

I did a quick scan on ebay, and i did find some 428 sprockets that you perhaps could have used. BUT all of them req. that you made new bolt holes, and that will req. a lathe to mark out the bolting circle.

I also found a 40 mm bolt on 428 sprocket:
http://cgi.ebay.com/ebaymotors/REAR-428-SPROCKET-40-MM-TONY-KART-CRG-BIREL-HONDA_W0QQcmdZViewItemQQ_trksidZp3286Q2ec0Q2em14QQhashZitem29fe621af7QQitemZ180361501431QQptZRaceQ5fCarQ5fParts

I you use this one, and you have a rather healthy engine, your stool wil go like ****.
I actually has a 125 racing kart, with about the same rear sprocket.
It has a water cooled YZ 125 cross engine, about 35 hp or so.
It will easily brake loose the rear tires in 1. gear...
Top speed is something like 70-80 mph...

I would search ebay (or other places) for 428 rear sprockets, and then make some measurments to see if it was possible to redrill, turn out center sections or whatverer to make it fit.
You could also try kart shops, 428 are used on racing karts, perhaps there is an old rear sprocket somewhere ?
Modern karts use 40 or 50 mm (or bigger) rear axles, and they often use sprockets like the one i linked to on ebay.

[GEEGONKEY]

LOOK'S COOL!!!Post a video when your done!

[Neverdone]

Installed the most important part today. The Swivel mount cup holder. Picture of my buddy testing it out.http://i248.photobucket.com/albums/gg164/RumbleWagon/billcrash.jpg

http://i248.photobucket.com/albums/gg164/RumbleWagon/cupholder.jpg

[shoyass]

Is that welded with Flux?

[Neverdone]

Most of it yes.... Would have preferred to do it with a different wleder but that is what I had and I can't stick weld worth a **** so that was out. It is holding up pretty well, but it is pretty dirty and splatters a lot. I went over some of the more crucial points with my friends mig since it is a lot hotter and gets better penetration.

[Neverdone]

Just a little update. Good thing I haven't ordered another rear sprocket yet. Was looking at the chain brushed it up some and found a few links (like 2 out of 100) that if you squint real hard and cock your head about thirty degrees say HK520 and after measuring it a few times have decided that the chain is a 520. I believe this is going to make finding a sprocket even harder, and I still havent been able to locate my 17x25x4 oil seal. I am begining to think that this will never get done...........

[Neverdone]

Well it doesn't appear that anyone is interested in my build anymore but I thought I would post an update anyhow. I finally found a sprocket, my chain is a 520 which is the same as a ANSII 50 but thinnner. I got a 20 tooth from grainger and had a 1/10th of an inch milled off it to get the chain to fit and then clamped it to my axle and I am using the stock chain from the bike. I finally have my oil seal and the motor holds oil now but I am still not able to get it started. I need to check a few things out on the motor. I haven't gave up hope on it yet but I am getting close. Updated pick of the back end:

http://i248.photobucket.com/albums/gg164/RumbleWagon/rear.jpg

[Heff]

Hey, been away for a bit up in the UP.Finally a nice weekend here in Michigan! I have to say ....Love the motor choice! How fast does it go??Nice job, Heff

[Neverdone]

All that is left now is to get it running. It is truly done other than any mods I want to do after the first run. Still can't get it started but have had it at least backfire now. The motor is a 79 YZ125. I put new reeds in it and it seems to have helped the compression some. Going to get a new plug for it and try that. Here is a Picture of the finished back end. http://i248.photobucket.com/albums/gg164/RumbleWagon/paintedback.jpg

[jjmorris]

Did you just paint that axle that color with spray paint or did you use another method? I just finished my barstool racer a few weeks ago but need to clean up my axle since its been sitting around for awhile. thanks

[Neverdone]

Sorry it took so long to get back to ya there bud. I painted it that color, but let me give you a tip. I took all my stuff off of the axle to paint it. That was a mistake. Mask it off and then paint it, it took me over an hour to get it all back on and then I had to repaint it because I scraped it all up putting the hubs and bearings back on.

On another note, I had it running for the first time today. Not necessarily well but running none the less. Took it down the street about 50 yards turned around and brought it back and shut it off. Never got out of first gear and it scared the crap out of me. Two things to note: 1. the cup holder is only good if there is something in it otherwise it vibrates and falls off. 2. DO NOT leave the swivel on the stool, I about spun off the top. I still need to do some carb work because it doesn't run very well and it smokes like hell, on top of that if I leave the gas on it just starts rolling out of the overflow on the back.

On a side note. The 10 seconds I was on it today riding down the street was awesome and definately worth the time and effort that I have put into it this summer working on it and building it!!! If anybody is thinking about doing it, take my word for it and just build one they are awesome....... Just you might want to pick a smaller motor than I did.

[Neverdone]

Thought I should put up a pick so everyone could see a mostly finished product have the blue rims on the front now, all painted and what not still just need the diamond plate from the floor boards.
Looks pretty good I think

http://i248.photobucket.com/albums/gg164/RumbleWagon/stool.jpg
If anyone wants to see it run:
http://s248.photobucket.com/albums/gg164/RumbleWagon/?action=view&current=stool_running.flv

[Smokin Ace]

I assume it is running then?

[Neverdone]

Yes but no. I have rode it down the street and back, but it is having issues with power. I believe that the motor needs a ring put in it/overhaul. Periodically it is running like a top and I have had it wound out in second gear and can already tell you that it is going to be too fast for its own good. :thumb:

[Smokin Ace]

Well it being too fast for its own good is a given :)

[Neverdone]

Well the way I see it is that it will never get boring because I will never be brave enough to peg it. At least not for a long time. Right now I am looking for a new upper end for the motor, freshin it up.

[DCHammer]

Nicely done. Bet it sounds great.

[Neverdone]

Well Just thought I would give a quick update. I put on a new UNI Pod filter and couldn't get the thing running, or once I got it running it didn't want to stay running. I decided that the motor just needed an overhaul. Checked the bore on the jug and it is at 58mm which is the farthest it can be bored. Not so good........... Well dug around on Ebay and found a guy that sold me a complete parts motor that has never been bored for $85 shipped to my door. Sop hopefully by next season, it will be ready for a real go round. The look shop said that they would bore it for me for $70 so now all I have to do is run down a piston. Also pretty glad for the find because now I have extra parts for my 30 year old bike motor. Hope I don't need them but if I do I will have them nice and tucked away for a rainy day.

[Neverdone]

Got the itch.......... Pulled it out of the shed the other day.......... Got it fired up and ran down the street. I can not wait for the new jug to be ready!!!! It is going to be stinky rediculous fast!!!!!!! I am going to work on fixing up the exhaust tomorrow so it will flow better, and also start building my hitch for when I build the cooler trailer. I am so excited for this summer it is pathetic!!!!!!!!!!!!!!!!

[Neverdone]

Finally found a piston, its on the way. Still haven't fixed the exhaust, hopefully tomorrow.

[Neverdone]

Worked on her again today, think I have the exhaust the way I want it. Now if I can just get that Jug back. http://i248.photobucket.com/albums/gg164/RumbleWagon/stuff1.jpg

[Neverdone]

So I just noticed that when I arranged all my pictures in my Photobucket, they are not shown on here anymore. If anyone would like to see the pictures and stuff here is the link

http://s248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/

[Neverdone]

Well still no jug, getting pretty iritated about that!! Rebuilt the motor mount of the weekend to include some rubber bushings to reduce vibration. Got it started for a few minutes for the first time in a long time. Motor is definitely worn out, you can hear the piston slap in the jug, but once you get it going it will run for about 15 minutes or so. Just long enough for me to go tearin down the street and swing a few doughnuts in my buddies yard that claims it doesn't run / never will. Made a believer out of him!!!!!!! I think I am going to switch to a bigger gear in the back to get some more bottom torque out of it. But maybe I better wait to get the jug and see what king of bottom it has then decide. In any case it has more top end than I know what to do with so maybe switch to a bigger gear so the the others in the trans arent just there for looks.

[Neverdone]

built the hitch to pull the trailer

http://i248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/hitch.jpg

[Neverdone]

Finally got my hydraulic brakes in yesterday!! Now I get to figure out how I am going to mount them. Also got my jug back from my friend that was SUPPOSED to be boring it for me... He had it for two months and never touched it. I guess I will have to take it to a real shop. The goal is to have it done in time for the Fort St cruise in June.

[Neverdone]

Well I finally got the caliper weldied on the back and the master cylinder on the front. Still need to finish my linkage between the brake pedal and master cylinder. Mounted the Resivior but not sure that I like where it is, but oh well it is there now. Oh and I need to make some clips to hold the brake line in place.

http://i248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/mastercylinder.jpg
http://i248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/caliper.jpg

[Neverdone]

breaks are done, have everything mounted, filled, bleed, and tested. Now they need a real road test, but have to have the jug done for that. Called monroe motorsports today to ask them about doing it. Will hopefully get thtat to them next week to have it done. Then off to try and finish the trailer, and mini bike...................

[Neverdone]

Dropped off the jug friday should get it anyday now!!! Got a new rear sprocket, 26t instead of 20, just have to mill it down. Also ordered some tailights for when I set up some electronics.....

[Neverdone]

Well I got the new jug on today!! Yesterday put on the new back sprocket, and built a chain tensioner. She needs a new carb gasket, and a carb tune, after that she is done for now!!! Had one of my friends take a little video of it, thought you guys might want to see...............

http://s248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/?action=view&current=VID_00013-20100617-2027.mp4

[fleebag]

Sounds like your doing all the right things. Should be cool after you get electronics.

[Neverdone]

Thanks Fleebag!! I need to find some sort of a generator to put on the thing to maintain a battery. I thought about using a bicycle generator, but I want to use something that puts out more power, and will have a "cleaner" look to it. I have a small 12v battery I can use from one of my RC plane starters. There is no way for an electric start, since it is a kick now, but I want to build a electronics box on it. In there put all the ignition equipment, a key switch, small battery, etc. That is the plan anyway. Here is one more pic for the build........
http://i248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/tensioner.jpg

[GuinnessGirl]

You've certainly been working a very, very, very long time on this project -- you must be LAZY!!!

:D ha ha ha. I'm kidding. I think it's amazing that anyone has the patience to even work on a project like this. I'm wondering if I'll even be able to get started. The pics look great and kudos to you finishing up! YAY!

[Neverdone]

well it has certainly been a long time comming on this project!!! But you know what they say....... You can't rush perfection!!! Well mine is certainly far from that but fun interesting to say the least. I found out last night too that it is not done yet :bigcry: !!! It is leaking out between the upperhead and jug. I have already placed an order for a new carb gasket, guess I am calling them now to correct the order and and the upper gasket to it. It is a copper head gasket, never saw one of those go bad before. Been my experience that you just spray them with a little copper coat and put them back on, but oh well.

[Neverdone]

Another quick vid, still havent got it tuned in yet but still having a blast with it!!!

http://s248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/?action=view&current=claysbarstool-1.mp4

Just to prove how much fun I am having on it zoom in on this picture and see for yourself. My buddie took this last night when I went cruisin by
http://i248.photobucket.com/albums/gg164/RumbleWagon/Little%20Zoom%20Zoom%20Bar%20Stool/claysbarstool.jpg

[Neverdone]

Well thought I would inform everyone that I got to see what happens when you crash my BSR the other day. First fire up of the year the other day when it was about 50 outside. My buddy across the street decided he would take it for a spin, 4th gear half to 3/4 throttle went head on into a 4ft tall snow pile. Luckily he flew into the yard and was not hurt. As for the BSR it suffered a bent shifter, and I rode it back to the shed and straightened it back out. He doesnt want to ride it anymore. He complimented me on my welding abilities, the frame or anything didnt budge an inche. Kind of impressive since it bounced up a curb before it hit the pile.